SINCOR

Sincor Document No: CA04-04-33-P-SP-020

Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 1/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

SINCOR, C.A.
UPSTREAM SURFACE FACILITIES PROJECT

DIESEL-DRIVEN EMERGENCY GENERATOR SET

REVISION INDEX:
This document consist of the following number of 22 pages

APPROVAL REGISTER

No. Prepared By/ Checked By/ Project Approved By/ Reason for Revision
Date Date Approved By/ Date
Date
A0 P.Bueno M.Gil Issued for IDC
99.03.18 99.03.19
0 M.Gil D. Baillie B. Docherty Issued for RFQ
99.03.26 99.03.26 99.03.26
X0 J.Menendez. A. Avila S. Cuesta J. Riera Update As Built by SINCOR
28-09-2005 28-09-2005 28-09-2005 28-09-2005 Rev 2005
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 2/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

TABLE OF CONTENTS
SECTION N PAGE
1. SCOPE........................................................................................................................................................................................3

2. APPLICABLE SPECIFICA TIONS AND STANDARDS..................................................................................................6

2.1 OTHER REQUIREMENTS .....................................................................................................................................................7

3. ENGINE GENERATOR SET PERFORMANCE, PACKAGING AND CONTROL SYSTEMS...........................8

3.1 EMISSIONS ..............................................................................................................................................................................12

4. ENGINE DATA AND DESIGN REQUIREMENTS .........................................................................................................13

4.1 DESIGN......................................................................................................................................................................................13

4.2 ENGINE AUXILIARIES...........................................................................................................................................................13

4.2.1 EXHAUST SYSTEM...............................................................................................................................................................13

4.2.2 COOLING SYSTEM...............................................................................................................................................................14

4.2.3. LUBE OIL SYSTEM...............................................................................................................................................................14

4.2.4. FUEL SYSTEM........................................................................................................................................................................15

4.2.5. STARTING SYSTEM..............................................................................................................................................................16

4.2.6. ENGINE GOVERNOR LOAD/SPEED REGULATION.................................................................................................17

5. GENERATOR DATA AND DESIGN REQUIREMENTS ...............................................................................................17

6. INSPECTION AND TEST......................................................................................................................................................19

6.1 FACTORY TEST......................................................................................................................................................................19

7. PREPARATION FOR SHIPMENT......................................................................................................................................20

8. DOCUMENTATION.................................................................................................................................................................21

9. NAMEPLATE............................................................................................................................................................................22
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 3/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

1. SCOPE

This specification covers the minimum requirements for an emergency diesel engine
driven generator sets in non-hazardous location. The intent is to permit the use of
Supplier-standard designs to the fullest degree consistent with the Buyers minimum
requirements for such services.

Compliance with this Specification shall not relieve the Seller of responsibility for
furnishing equipment of proper design, construction and scope of supply, fully suitable for
all specified operating conditions.

All exceptions, comments and clarifications to this Specification shall be addressed in the
proposal, by specific reference to the applicable article.

The Seller shall design, manufacture, test and ship a diesel generator package, designed
for a service life of at least 20 years when operating up to 1000 hours/year. It shall also be
capable of continuously operating at its rated output for at least 1000 hours (exclusive of
any necessary oil changes). That is, the quoted output shall be its prime rating including
10% overload capability per ISO 3046/1.

The equipment shall be complete within the scope of supply boundaries specified,
including all components, systems and features required for the specified service(s) and
for the characteristics of the Sellers design, whether or not such items are individually
cited in the technical specification or Purchase order and whether or not the terms
standard or Suppliers standard are used.

The Seller shall state in his proposal the recommended intervals for the following service
requirements:

Oil change

Valve adjustment

Top end adjustment

Major overhaul

The preferred intervals are as follows:

SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 4/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

Oil change 500 hours

Valve adjustment 2000 hours

Top end adjustment 4000 hours

Major overhaul 10000 hours

If these preferred intervals are not met with the standard design but can be met with some
modification, the modification and extra cost associated with same shall be identified in
the proposal.

The Seller, if different from the engine manufacturer, shall be an authorized assembler of
the engine manufacturer and shall be qualified to furnish diesel generator packages by
demonstrating at least 10 years experience in the design and construction of equipment
having similar output, operating conditions, and configuration. The generating unit and
accessories shall be rated for standby service and capable of accepting the specified
loads and providing the specified power output for the duration of the utility power failure.

The experience list included in the proposal for the equipment shall include at least two
(2) examples of each of the types/models proposed, in equal-to or more severe service
than the proposed equipment as regards the principal operational parameters (e.g.
speed, output power) and manufactured at the same factory as applies to the equipment
proposed. Both of such units shall have accumulated a minimum of two years of
successful field operation. No new design or unproven (per the above criteria) equipment
components shall be provided, except as a proposal-stated exception to the Buyer in the
standard with subsequent acceptance of such exception by the Purchase Order.
Alternative designs may be quoted to utilize Supplier-standard equipment and assist in
meeting this experience requirement, subject to the same exception and approval
process.

The Sellers scope of supply shall include:

1. One diesel engine driven generator. Diesel Engine Generator Set shall be self-
contained and not rely on any plant utilities other than electrical power for battery
charging.

2. Fabricated steel skid common to the engine and generator.

SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 5/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

3. Vibration isolators

4. Engine cooling, fuel and lubrication systems.

5. Voltage regulation system.

6. Electronics governors system.

7. Main line circuit breaker with 100% rating and shunt trip, line side and neutral
side cubicles, neutral grounding and protective devices.

8. Automatic transfer switch consisting of an inherently double-throw power transfer

switch unit and a control module interconnected to provide complete automatic operation.
The contact transfer time in either direction shall not exceed 17 seconds.

It shall be suitable for connecting the equipment to and disconnecting it from an otherwise
dead bus, and shall include sensors and controls to preclude the attempting of closure to a
live bus. (Price is to be shown separately).

9. Automatic starting, control, speed electronic governing and engine protection

system(s), including static type with silicon controlled rectifier voltage regulator and
electromagnetic interference suppression.

10. Battery system, charger and rack with clamp and interconnecting cables.

11. Air intake system including louvers, air inlet grille and filters.

12. Exhaust system including silencer with flexible connection, pipe supports, drain,
weather shield and hinged rain cap.

13. Fuel tank(s) with float switch, manual fill, vent, level gauge, and drain, sized for
24 hours operation at full load and fuel delivery system. Price for tank(s) is to be shown
separately.

14. One set of special tools.

15. Start-up spares (to be identified in the proposal) (Price is to be shown

separately).

16. Documentation.

17. Factory load testing.

SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
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UPSTREAM SURFACE FACILITIES PROJECT Page /File: 6/CA04-04-33-P-SP-020
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18. Availability of Sellers services for site commissioning and testing. (Price is to
be shown separately).

The Buyers scope of supply will include:

1. Wiring and piping external to the package. The Seller shall define in his
proposal the extent of wiring and piping it will complete and the extent of wiring and piping
required of the Company.

2. Utilities, fluids and fuel

Foundations with reinforced concrete base cons truction are by others

2. APPLICABLE SINCOR SPECIFICATIONS AND STANDARDS

The standby diesel generator package and its constituent parts shall comply with :

Standards of the International Electrotechnical Commission (IEC).

IEC 60034 Rotating Electrical Machines

IEC 60085 Thermal Classification of Electrical Insulation

IEC 60255 Electrical Relays

IEC 60529 Classification of Degree of Protection Provided by Enclosures

NFPA 110 (Level 1).

Standard Practice for Stationary Diesel Engines of the Diesel Engines Manufacturers
Association (DEMA).

SINCOR Specifications:

CA04-04-33-P-DC-101 Electrical System Design Criteria

CA04-04-33-P-SP-012 Electrical Requirements for Packaged Equipment

CA04-00-00-G-SP-018 Painting
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 7/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

Other referenced Specification stated in the Material Requisition or in the Purchase Order
may complement or modify the standards specified. The most recent edition of the
referenced standard that has been published at the time of purchase order execution shall
apply in all cases.

All components classifiable as pressure vessels under Section VIII of the ASME Boiler
and Pressure Vessel Code shall bear an ASME stamp certifying compliance with this
code or a stamp certifying compliance with a Buyer-approved foreign code.

Motors, generators, electrical components and electrical systems shall be in compliance

with Covenin 200, which is the national electric code of Venezuela.

2.1 OTHER REQUIREMENTS

The presence of any corrosive reactive and hazardous agents in the fuel and in the
environment is identified, but their maximum amount is sometimes unknown. The Seller
shall advise in the proposal concentration limitations for such agents specified.

The Seller shall assume for cooling and other non-demineralized water that the chlorides
concentration is high enough to preclude the use of materials subject to chloride stress
corrosion cracking.

In order to comply with Venezuelan requirements concerning exposure of plant personnel

to noise, individual noise sources shall be limited, where possible, to the following sound
pressure levels:

a. 85 dBA at 1 meter from the source of the noise, unless approved by Buyer. The Seller
shall achieve this condition as a contractual requirement for the equipment in its basic
state (i.e. with no special sound treatment provisions). If meeting this criteria will result in
excessive costs, then the Seller is requested to do both of the following:

- State in the proposal an exception to the specification in this respect.

- Quote an option for the achieving of this condition, based on descending cost
associated with noise levels identified in Item b, below.

b. It should be noted that "8 hr. time weighted average" exposure to sound pressure levels
in excess of 85 dBA may require audiometric e t sting or personnel use of individual
"hearing protective devices". Therefore, in-plant noise shall be limited to 85 dBA, unless
approved by the Buyer. [Note that noise levels of up to 88 and 91 dBA are considered
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 8/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

acceptable where exposure levels are less than 4 and 2 hours, respectively per Covenin
1565:1995].

The equipment will thereafter be acceptable only with the Buyers approval in its basic
state or (as decided by the Buyer) with purchase of the noise abatement option quoted.

The maximum free-field noise level shall also in no case exceed 120 dB(A) for the
measurement locations cited above, for noise from infrequently encountered and
emergency events such as the opening of relief, vent and blowoff valves. Noise
abatement measures shall, in all cases, be included in the base bid if and when needed to
comply with this criterion.

The Seller shall be responsible for designing and implementing any modification required
to reduce the noise to a level authorized by local regulations at the place of use if the
above -described 85 dB(A) basic-state commitment is made in the proposal but not
achieved onsite, or if the quoted option is purchased but fails to produce the required
effect, or if the aforementioned 120 dB(A) requirement is not achieved onsite.

Use of asbestos, asbestos compounds and polychlorinated byphenyls (PCBs) is not

acceptable. All equipment and component materials shall be new and unused.

Copper and copper-bearing alloys shall not be used, except where required in electrical
systems. The equipment, including such systems and with particular consideration given
to control panels and the like, shall however have the design life specified when exposed
to the jobsites H2S levels (estimated at 20 micrograms/m3) as well as the humid, and
rainy environment cited earlier in this specification.

3. ENGINE GENERATOR SET PERFORMANCE, PACKAGING AND CONTROL

SYSTEMS

The Seller shall have unit responsibility for the diesel engine generator set.

Unit responsibility refers to technical responsibility for all characteristics and components
of the equipment, whether considered individually or in terms of interactions (e.g. driver
and driven equipment arrangement, power requirements, speed, direction of rotation,
rotodynamics), including finishes, testing, preparation for shipment and documentation,
irrespective of whether or not the Seller is the manufacturer of the covered components.

The unit(s) shall be capable of unattended remote automatic starting. The engines and
generators shall be capable of being started and exercised under part or full load for a
period of at least two hours per week. The Seller shall supply all the necessary equipment
to insure successful operation under the specified operating conditions.
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 9/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

The combined unit shall operate at all loads up to and including rated load without
excessive lateral and torsional vibration over the speed range of 90 - 125% of rated
speed. There shall be no harmful transient modes during ramp up to operating speed.

The engine/generator and radiator package set shall be assembled on a common base
by the manufacturer. This package shall comply with SINCOR Specification # CA04-04-
33-P-SP-012.

The generator set base shall be designed by the Seller to resist deflection, maintain
alignment, and minimize resonant vibration. The Seller shall submit a torsional vibration
analysis to verify the engine generator set is free from harmful stresses and vibration. All
necessary subsystems (such as lube oil or cooling water) shall be mounted within the
confines of the baseplates.

The baseplate(s) shall be of structural steel frame design, with full-depth continuous -weld
cross members. Lateral or transverse beams shall be located at all machinery supports,
or the supports must attach to the axial rails with sufficient stiffness that deflection-related
problems do not occur at the Sellers maximum allowed interconnect forces and moments.
Vibratory stress relief shall be applied prior to baseplate machining if and where required
to prevent stress relieving-related distortion in service.

Baseplate shall be furnished with leveling jackscrews adjacent to each anchor bolt
opening. Vertical corners of the baseplate shall be rounded to a 50 mm minimum radius
to minimize grout cracking.

Engine and generator shall be direct connected using a torsionally resilient non-lubricated
coupling with a continuous duty service factor of 2.5 minimum. Coupling, flywheel and
other rotating members shall be guarded and meet OSHA standards.

Couplings shall sustain without damage the maximum starting and fault torques that can
be experienced for the driver type specified, including attempted out-of-phase breaker
closing.

Steel spring isolators shall be installed between the generator set base and the mounting
surface. The isolators shall bolt to the base, and have a waffled or ribbed pad on their
bottom surface. The pads shall be resistant to heat and age, and impervious to oil, water,
antifreeze, diesel fuel, and cleaning compounds. Vibration isolators shall be classified for
Seismic Zone 1 per UBC.

A control panel and all accessories shall be provided as indicated in the Material
Requisition. All accessories and components not specifically mentioned, but required to
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 10/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

make the unit perform its intended function within the specified environment, shall be
provided.

1. The Seller shall design and furnish one (1) IP 55 control panel mounted on the
generator set with vibration isolators.

2. As a minimum, the following shall be displayed or present on the control panel:

generator displays as indicated in this specification, automatic engine start/stop
controls with adjustable crank duration, number of starts and Manual-Off-Auto start
selector switch.

3. The required warning functions include: Pre-High jacket coolant temperature,

pre-low oil pressure, pre -high oil temperature, pre-low coolant low level, low coolant
temperature, control switch not in Auto, air damper closed, battery charger
malfunction, low battery voltage, and low fuel level. Visual and audible indication shall
be furnished.

4. The required fault/shutdown functions include: High jacket coolant temperature,

low oil pressure, high oil temperature, engine overspeed (redundant systems), loss of
speed signal, engine overcrank, and low coolant level. Visual and audible indication
shall be furnished.

If a programmable logic controller (PLC) is used, it shall be subject to Buyers

approval, to avoid proliferation of PLC types at the jobsite.

5. The following items shall also be included: lamp test switch, alarm horn and
silence switch, voltage adjus tment control, governor speed control, operating hours
display, engine lube oil temperature, coolant temperature, battery voltage, engine
speed.

6. All necessary control wiring, wiring harnesses and sockets, illumination, fuses,
fuse blocks, terminal blocks, nameplates, fault connections, auxiliary contacts, PTs
and CTs shall be furnished by the Seller.

7. The Seller shall provide an annunciator panel in a IP23 enclosure, for separate
installation in a Buyer provided building. The annunciator shall be provided with an
auxiliary contact, pre-wired to a set of dedicated terminals to indicate Generator Set
Common Trouble Alarm, for wiring by others to the plant Distributed Control System
(DCS).

Dry contacts for generator set alarm and trip functions shall be provided to indicate all
abnormal functions.
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 11/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

The engine-generator unit and accessories shall be capable of operating at 125% of

rated speed without over stressing any part of the engine, generator and/or accessories.
The engine will be exercised weekly by running it at rated load for at least 30 minutes. The
requirements of section 4, above, still apply.

The package shall be all-inclusive and self-contained as regards control, sequencing,

protective (including start permissive) and monitoring systems, exc ept for the following:

- Specified Buyers-input signals to the Sellers control system.

- Control systems specified in the Material Requisitions to not be Seller-supplied.

- Manual pre-start operations identified in the Sellers proposal.

That is, the Sellers control system shall monitor, sequence, control and protect all
equipment that the Seller supplies, unless direct instructions to the contrary appear in the
Material Requisition.

All solid-state controls programming shall be field-adjustable. That is, PROM chips are
not acceptable, unless they can be erased and reprogrammed at the jobsite; and, if they
are used, the Seller shall provide the device(s) and instructions needed for such work.

A first-out annunciation feature shall be provided.

An emergency shutdown pull-switch (or pushbutton shielded against inadvertent

activation) shall be provided at the unit-mounted control panel.

The equipment shall be fail-safe; i.e. automatically proceeding to the stopped,

deenergized and depressurized condition in response to a shutdown command. Stored
energy devices shall be included, such that fail-safety is not conditional upon the Sellers
supply of electric power, compressed air, other utility services or operator intervention.

Electrical materials shall be selected and treated for a tropical environment as indicated in
Data Sheet. Space heaters shall be provided. The engine-generator set and
accessories shall be completely wired and assembled. All wires and terminals shall be
tagged with wire numbers.

All wiring for baseplate-mounted equipment shall be routed to an interconnect marshalling

box or boxes, as opposed to requiring Buyer interconnects to individual on-skid
instrumentation items and terminal heads. Analog control, binary control and power
electrical wiring shall be segregated in conduit runs and junction boxes, as required to
prevent inductive interference problems.
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 12/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

Components requiring lifting for maintenance shall have sturdy and secure provisions for
the attachment of lifting devices. The attached item, such as an eye bolt, shall be part of
the permanent equipment or special tools.

Bolting 50 mm in diameter and larger shall be tightened by controlled stretching. A

hydraulic or heater tool for this purpose shall be provided, as part of the Sellers special
tools, if such tools are used. Other special tools provided shall include those necessary
for handling, dismantling, reassembling and adjusting the diaphragms, end covers and
other major components as applicable.

Any special tools or fixtures required for installation and maintenance. The special tools
shall include any interrogation device(s) and/or software needed for full-authority
interrogation and troubleshooting of solid-state control system. Passwords for solid-state
control systems shall be provided as a special tool.

A mechanical barring device, interlocked to prevent engine cranking or starting when

engaged, shall be included.

3.1 EMISSIONS

The Seller shall provide in the proposal not-to-exceed emissions guarantees in the
following format. All ppm values are to be reported dry to a referenced 02 level of 15%, at
rated speed and with standard timing.

GEN % NOX CO TOTAL CO2 PART O2(DRY) SMOKE BOSCH

PWR LOAD (as ppmv HC % Vol MATTER IN EXH OPAC SMOKE
Kwe NO2) ppmv ppmv (VOL) % NO.
ppmv %
100
75
50
25
10

Emissions guarantees shall be in effect in perpetuity, i.e., they shall not be wear and tear
related. They shall be inclusive of all tolerances for measurement uncertainty, include
statistical manufacturing variability and related factors. All corrections or modifications
required to attain guaranteed emission levels shall be made by the Seller at his expense.
CO shall not exceed 1150 ppm and NOx shall not exceed 150 ppm, dry as measured in
both cases.
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4. ENGINE DATA AND DESIGN REQUIREMENTS

4.1 DESIGN

The engines driver power rating shall be the power available at the engine coupling after
any derating for type of service, altitude, summer ambient temperature, fuel quality, and
after subtracting engine power absorbed by auxiliary equipment driven from the engine
shaft.

Brake mean effective pressure (BMEP)and engine -generator efficiency definitions shall
conform with standards cited earlier.

The design brake mean effective pressure (BMEP) shall not exceed 13 bar. The kW/cm2
of piston area shall not exceed 0.3. The speed shall not exceed 1800 RPM.

The unit(s) shall have the ability to recover from transients, load applications, and load
removals equal to a 20% increment of rated load, such that the frequency change does not
exceed 3% and the duration is less than six (6) seconds. It shall also have the ability to
recover from transients, load applications and load removals equal to a 20% increment of
rated load, such that the voltage drop or rise does not exceed 20% and the duration is
less than six (6) seconds.

The engines required auxiliaries, the guarantees of fuel consumption, acceptance tests,
governor performance, torsional vibration, materials and workmanship shall be in
accordance with DEMA standard practice.

Cylinder liners shall be of the wet, removable type.

Crankcase pressure safety relief devices shall be included.

4.2 ENGINE AUXILIARIES

4.2.1 EXHAUST SYSTEM

The Seller shall provide the air intake systems, including louvers and air filter, at the
engine. The intake system shall be suitable for the specific ambient conditions, and shall
not allow rain to be drawn into the engine.

The Vendor shall provide a low backpressure exhaust system including dry manifolds,
piping, stainless steel flexible connectors, suitable supports and vibration isolators,
silencers, spark arresters, exhaust condensate trap with manual drain valve and weather
caps. All exhaust surfaces up to a level 2.5 m above grade or work platforms sha ll be
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 14/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

provided with personnel protection such that the maximum surface temperature does not
exceed 65C.

The Vendor shall provide separate outlets for the engine crankcase breathers connected
to the radiator exhaust duct flange.

4.2.2 COOLING SYSTEM

The engine cooling system shall consist of a unit-mounted, vertical core, fin-and-tube
radiator with expansion tank and blower fan sized to adequately cool the engine when the
diesel generator set is delivering a minimum of 110 percent of the full rated load at an
ambient air temperature of 40C. A radiator duct flange shall be provided.

The fan and all rotating members and drive belts shall be guarded and meet Venezuelan
standards. Proof of ambient temperature capability at the site elevation shall be furnished
with calculations by the radiator manufacturer.

Maximum static air flow restriction shall not exceed 12 mm water gauge external.

A radiator-mounted coolant level sensor shall be provided to indicate coolant level in

radiator and to signal a low coolant condition back to the unit-mounted control panel.

Jacket water heaters shall be provided to maintain coolant temperature of 32C to 46C
while the engine is idle. Heaters shall include thermostatic controls. Jacket water
isolation valves shall be provided on the inlet and return sides for ease of maintenance.
The heaters shall automatically disconnect when the engine starts.

The engine generator vendor shall coordinate to make sure that intake and exhaust
systems are properly sized to meet specification requirements and to provide for proper
operation of the equipment.

4.2.3. LUBE OIL SYSTEM

The Vendor shall furnish a lube oil system for each diesel generator unit consisting of the
following items:

Engine-driven lube oil pump capable of discharging the maximum required flow of engine
lubricating and piston cooling oil at all operating conditions. The pump shall be equipped
with a suitable relief valve.
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 15/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

Simplex lube oil strainer capable of straining the full flow of lube oil at the maximum
viscosity, without starving the lube oil pump.

Lube oil heaters (if necessary) to ensure that oil temperature is maintained at a value that
will allow the engine to start and come up to load within 12 seconds.

A wet sump with a capacity large enough to contain all the oil in the engine shall be an
integral part of the diesel generator skid.

The lubrication oil pump shall be a positive displacement type that is integral with the
engine and gear driven from the engine gear train. The system shall incorporate full flow
filtration with bypass valve to continue lubrication in the event of filter clogging.

The engine shall be designed with oil retention features to eliminate potential damage
from dry starting without use of a prelube pump system.

4.2.4. FUEL SYSTEM

The fuel system shall be integral with the engine. It shall consist of fuel filter, transfer pump,
injection pump, lines and nozzles. A fuel/water separator shall be provided to protect the
fuel system from water damage. The pumps shall alter the volume of fuel delivered to the
spray nozzles according to load demand. The nozzles shall inject fuel directly into the
cylinder in the optimum spray pattern for efficient combustion.

The fuel system shall also include a day tank and a main tank sized as noted in the
requisition.

The main tank shall be buried outside the blast resistant building and equipped with the
necessary vent and fill piping. The main tank will feed the day tank using an electric motor
driven pump but will also have a manual pump to bypass the motor driven pump in the
case of a loss of power.

Both tanks will have level control transmitters for local indication and remote indication to
the diesel generator panel. The main tank will have a double shell with means of detecting
leakage from the inner tank and a manual shutoff valve between the main tank and the day
tank. The manual shutoff valve must be located outside the engine generator room and be
readily accessible.

Flexible fuel lines between engine and fuel supply shall be installed to isolate vibration. A
manual fuel priming pump shall be included to facilitate priming and bleeding air from the
fuel system.
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Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 16/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

The Vendor shall state in the proposal its fuel quality requirements, including any limits in
this respect for the emissions guarantees of section below.

4.2.5. STARTING SYSTEM

A DC electric starting system with positive engagement drive shall be furnished. The
starting motor shall have adequate torque to bring the engine-generator to full frequency
and voltage from a cold start and be re ady to assume load in less than ten (10) seconds.

The engine starting system shall include a DC electric starting motor, starter relays, and
automatic reset circuit breaker.

Fully automatic generator set start-stop controls in the generator control panel shall be
provided. Controls shall include a 30 second single cranking cycle limit with lockout.

24 VDC sealed Ni -cad batteries shall be furnished for engine starting and control power.
Batteries shall be selected and supplied by the Vendor. Batteries shall be sized to insure
a minimum of nine consecutive ten second cranking attempts. Batteries shall be located
as close to the starting motor as practical, away from spark sources, and permit easy
inspection and maintenance. The battery voltage shall be compatible with the starting
system. Chemically resistant battery rack and necessary cables and clamps shall be
provided. Thermostatically controlled battery heater pads shall be furnished by the Vendor
to maintain the required minimum battery temperature at the lowest ambient air
temperature specified.

A dual-rate constant-voltage battery charger shall be provided, which shall accept power
as defined in the data Sheet input to provide 24 VDC output. It shall be fused on the AC
input and DC output, and sha ll incorporate current limiting circuitry to avoid the need for a
crank disconnect relay. An AC voltage power switch shall be mounted on the face of the
charger and shielded from accidental switching. The charger shall include an AC
ammeter and voltmeter, and be housed in a IP 54 enclosure suitable for indoor mounting.
Charger shall be capable of fully recharging batteries in 8 hours.

Charger shall be provided with the following accessories:

- Low DC Voltage Alarm Relay

- 0-24 Hr. Automatic Equalizer Timer

- Battery Charger Malfunction Alarm Relay

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Sincor Document No: CA04-04-33-P-SP-020
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Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 17/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

4.2.6. ENGINE GOVERNOR LOAD/SPEED REGULATION

Each engine shall be equipped with an electronic governing system capable of

maintaining the generator speed within the specified limits, from no load to full rated load
of variable adjustment to isochronous operation. The Seller shall include the equipment
required (e.g., PTs, CTs, actuator, control box), to integrate the governing system into the
electrical system.

The engine governor shall be a Woodward 2301A load share type or as approved by
Buyer. Each generator set shall be capable of operating alone, (isochronous mode).
Speed droop shall be externally adjustable from 0 to 5% from no load to full rated load.
Steady state frequency regulation shall be 0.25% from no load to full rated load. Speed
shall be sensed by a magnetic pickup off the engine flywheel ring gear. A provision for
remote speed adjustment shall be included. In the event of a DC power loss, the forward
acting actuator will move to minimum fuel position.

The electronic governor shall respond to a speed change of .1% and shall operate without
hunting for all values of speed droop and load.

The governor shall be equipped with a reversible synchronizing motor arranged for
operation on the available low voltage supply. An auto -synchronizer with provisions for
manual synchronizing shall be provided for each unit. The Seller shall also supply, when
multiple generator sets are specified in the Material Requisition, a complete system for
synchronizing the island bus to the utility system.

Each engine shall be furnished with a speed sensor and two speed indicating instruments.

Scavenging blowers shall be included for two-cycle engines.

5. GENERATOR DATA AND DESIGN REQUIREMENTS

Each generator shall have rated capacity not less than the figure cited in the Material
Requisition, at (unless specified differently in the Material Requisition) 0.80 lagging PF,
WYE connected, 3 phase, 60 Hz.

Generator performance, rating, manufacturing and testing shall comply with the
requirements of IEC 60034/1.

The engine-generator unit shall consist of an alternating current generator with direct
connected, brushless permanent magnet exciter, with a dual DC electric starting system,
accessories, and auxiliary equipment as listed in this specification.
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Sincor Document No: CA04-04-33-P-SP-020
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UPSTREAM SURFACE FACILITIES PROJECT Page /File: 18/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

The harmonic content (THD) shall not exceed 3%, and the generator shall have 2/3
winding pitch.

The generators shall have Class F vacuum pressure impregnated mica-epoxy insulation
system with a temperature rise limited to Class F total temperature, drip proof (ODP)
enclosures, intrinsically safe (to Ex ia) stator and bearing temp detectors with monitors,
space heaters, separately mounted static voltage regulator, reactive current
compensation for parallel operation, voltage adjusting rheostat and manual control.

Armature windings shall be interchangeable form wound coils. The coils shall be held
securely in the slot by wedges. The end windings and connections shall be capable of
withstanding short circuit currents without damage.

A voltage regulator shall be provided to match the characteristic of the generator and
engine. The voltage regulator sensitivity shall be 0.5%. The excitation regulation system
shall insure rapid and high voltage recovery when starting large motor loads.

The generator, voltage regulator and excitation system shall be capable of one hundred
percent full load application and 0 -100 percent load shedding.

Generator switchgear shall be provided to contain the static exciter voltage regulator unit
and the following equipment:

1. Current Transformer (CT), Potential Transformers (PT) and Transducers as

required.

2. Wattmeter & Frequency Meter.

3. Grounding Equipment with Ground Fault Alarm.

4. Generator - Field Ground Relay.

5. Loss of Excitation Relay, Stator Impedance Type.

6. Generator Over Current Relay.

7. Under and Over Voltage Relay.

8. Power Factor Meter.

9. Voltmeter and Ammeter to Monitor Excitation Voltage and Current.

10. One (1) Voltmeter and Ammeter with their Corresponding Switches to Monitor
Generator Current and Voltage.
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Sincor Document No: CA04-04-33-P-SP-020
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Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 19/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

The generator shall have a Short Circuit Ratio that meets IEC requirements. This figure
shall be not less than 0.50 and the saturated subtransient reactance shall be not less than
0.11, unless higher requirements are specified in the Material Requisitions.

6. INSPECTION AND TEST

The Buyer reserves the right to witness complete unit testing. A minimum of five (5)
working days notice shall be given for observed and witnessed tests.

Any observation and witness points other than the complete-unit test will be stated in the
Material Requisition. The Seller shall host a pre-inspection meeting after-order, to
coordinate the Buyers traveling for witnessing and observing of tests and inspections.

Materials certificates, including heat treatment records where required, shall be obtained
by the Seller for major rotating parts, casings and ASME code-stamped vessels pressure-
containing components. Copies of such certificates shall be provided to the Buyers
inspector upon request or, other than for ASME code-stamped vessels, shall be exhibited,
if the Seller considers them to be proprietary.

The Seller is responsible for identification and implementation of examinations necessary

for assurance of quality for the service(s) specified. The Seller shall identify in the
proposal its standard, general quality assurance procedures, i.e. the quality plan.

6.1 FACTORY TEST

Hydrostatic test shall be applied to all tanks and piping. Tanks shall be tested to UL
requirements, other required national standards or in accordance with applicable ASME
codes for unfired pressure vessels.

The diesel engine generator set with accessories (as a minimum: completely assembled
diesel, generator, and radiator mounted on the base, and control panel with annunciator)
shall be given a complete test at the Sellers factory. Certified test data and performance
results shall be reviewed and approved by the Buyer prior to release for shipment. The
Buyer intends to witness the performance as well as functional tests. The diesel engine
shall be tested in accordance with the requirements of DEMA. The generator shall be
tested in accordance with applicable IEC standards.

Equipment shall be tested attached to a shop floor surface or to a bedplate of mass and
rigidity sufficient to render the factory test vibration results applicable to the machinerys
field-installed condition. Correction factors shall not be applied or necessary to correlate
factory test vibration measurements to equivalent field figures, nor shall apparatus, other
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Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 20/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

than the units standard resilient support elements, be applied for this purpose during
factory testing.

Testing shall demonstrate that the time required to start a cold engine (using only the
coolant jacket heaters) to full frequency and voltage (ready to accept load) can be
achieved within ten (10) seconds.

A four (4) hour load test is required: one (1) hour at 50% load, one (1) hour at 75%, and
two (2) hours at 100% load. Testing shall be done at the rated power factor. Testing at
unity power factor is not acceptable. Data shall be recorded per NFPA 110 or IEC
equivalent.

All protective devices, controls and instrumentation shall be given a functional test. The
overspeed (governor) shut down function shall be demonstrated by manually overriding the
governor and noting the speed at which the engine is shut down. Required limit is with a
tolerance of 1%.

Equivalent specified load applications and removals shall be made to verify that the
voltage and frequency recovery are within the specified limits. Data shall be automatically
charted, to document the recovery curve.

Documentation shall be provided that all auxiliaries have been tested in accordance with
the requirements and to demonstrate compliance with the guarantees.

All factory performance testing shall contain the appropriate correction factors for the site
conditions. The correction factors shall be clearly stated in the test report.

Any disassembly after test shall be limited to the minimum necessary to ensure damage-
free and specified dimensional/weight limit-conforming transportability. Shipment of
equipment in a piece-part, uncompleted or discrepant state is prohibited.

The Buyers approval of test and other pertinent specified data is required for
authorization to ship the equipment. Equipment acceptance by the Company at the
Sellers factory or onsite shall not constitute a waiver or modification of any specified
requirements.

7. PREPARATION FOR SHIPMENT

The Seller is responsible, regardless of the shipping terms specified, whenever shipments
to site originate from the Sellers factory(ies) for the technical task of ensuring at the
factory(ies) that the equipment is secured for the means of transportation and braced so
as to not have it damaged in transport by humping of railcars, the movement of ships at
sea, being rolled off a truck and the like as applicable.
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 21/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

All equipment will be inspected prior to shipment.

All piping shall be installed and properly supported for shipment, unless otherwise
approved by Buyer.

The Seller shall submit the recommended storage requirements for this package.

All equipment and all instruments shall be physically tagged with the appropriate item
numbers as supplied by the Buyer. In general, stainless steel tags (foil not acceptable)
shall be used and attached with stainless wire. This applies to all equipment and
instruments whether shipped as part of a package or shipped separately.

Painting shall be in accordance with SINCOR Specification CA04-00-00-G-SP-018, with

the following additional requirements and clarifications:

- Painting shall be warranted for five (5) years from the date of shipment of the equipment
as regards chipping, peeling, blistering and other forms of failure to protect the surfaces
covered.

- Machined surfaces, such as mounting pads for the feet of rotating equipment, shall be
included among the surfaces not painted.

- Section 3 of Spec CA04-00-00-G-SP-018 shall not be interpreted as allowing a

variation of colors and painting systems between components manufactured by the S eller.
The Seller having unit responsibility shall for all equipment packages ensure that they are
uniformly painted, and the painting system to used shall be identified in the proposal.

- The references to field painting in section 3 and elsewhere in Spec CA04-00-00-G-SP-

018 do not apply to mechanical equipment. All painting of such equipment shall be
performed by the Supplier prior to shipment per section 3, including any piping or other
components shipped loose.

8. DOCUMENTATION

Seller shall furnish drawings and data in the form and quantity as specified in Material
Requisition.

The as-manufactured accuracy criteria for drawing dimensions pertaining to Buyer

interfaces shall be 13 mm for major fluid connections, 25 mm for other fluid and electrical
connections and 6 mm for anchor bolt locations.
SINCOR
Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 22/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

Generator data for systems study shall be submitted by Seller within the agreed upon time
frame after order. In addition, the following generator curves and characteristics shall be
submitted to Buyer:

Operating data and performance curves including but not limited to reactive capability
curve, excitation v curves, saturation curves, decrement time versus current curve, exciter
constants/expected harmonic data, excitation and voltage regulator data including block
diagram.

1. Elementary Interconnecting Wiring Diagrams

2. Elementary Schematics

3. Summary of Control Components

The Seller shall guarantee, based on the field test at the packager, the following:

1. The net power output in kilowatts, adjusted for the actual site conditions.

2. Fuel oil consumption in kg per KW HR at 50%, 75% and full load.

3. Lube oil consumption in liters per hour.

4. The generator operates to the conditions described in this specification.

Emissions, using the format presented in this specification.

9. NAMEPLATE

Nameplate shall be of stainless steel, be permanently fixed to a non removable part of the
equipment, and constraint, at least but not limited to the following aspects :

1. Address and name of the equipment (engine, generato r and transfer switch)
manufacturer.

2. Type, model and serial number of equipment.

3. Nominal voltage and phase number.

4. Nominal frequency.

5. Diesel engine mechanical nominal potential.

6. Speed of rotation.
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Sincor Document No: CA04-04-33-P-SP-020
Sincor Interface Code: 0
Project Title: SINCOR, C. A. Sincor Document CLASS: 00
UPSTREAM SURFACE FACILITIES PROJECT Page /File: 23/CA04-04-33-P-SP-020
Rev./Date: X0 / Sept-2005

7. Diesel consumption.

8. Battery voltage.

9. Manufactured data.

10. Total weight.